Polylactic acid‐based composite using fused filament fabrication: Process optimization and biomedical application

Biopolymer-based composites, which are being employed extensively in biomedical applications have exceptional physical and mechanical properties. However, printing composites is a challenging task for biomedical applications. The current work highlights the impact of process parameters of fused filament fabrication (FFF) technology, that is, layer height, number of loops, nozzle temperature, and a nonprocess parameter, that is, weight percentage of alumina on ultimate tensile strength, ultimate flexural strength, and ultimate compression strength of polylactic acid (PLA)-alumina composite. Response surface methodology (RSM) has been implemented to construct the tests. The regression model demonstrated how various parameters and their interaction affected output responses. The surface plots for noticeable interactions have also been plotted. The outcome revealed that parameter control and optimization have vital impact on mechanical properties. The optimum value for maximum mechanical strengths has been obtained at layer height 0.1 mm, number of loops 4, nozzle temperature 195 degrees C, and weight percentage of alumina as 1.5%. Later a case study has been performed with obtained optimized parameters with porous structures for biomedical applications and found that the properties such as surface finish, and dimensional accuracy were unaltered during the optimization process.